Attachment 7 - Air Handlers Control System Specifications 8-2025.pdf

AIR HANDLERS CONTROL SYSTEM

PART 1 - GENERAL

1.1 SUMMARY

A. Section includes the general requirements for the Integrated Automation systems.

Integrated Automation Systems are utilized on Production equipment and systems, chiller and boiler plants, scrap processing and dust collection systems, electrical substations, HVAC equipment, pollution control equipment, air, water(domestic hot and chilled) , steam and natural gas systems.

B. Related Sections:

1. All sections within Division 25.

2. Section 23 00 00 – Heating, Ventilating and Air Conditioning

3. Section 26 00 00- Electrical

4. Section 45 00 00-Industry-Specific Manufacturing Equipment

C. Where architectural features govern location of work, refer to architectural drawings and coordinate with other trades.

1.2 REFERENCES

A. This section includes any rules and regulations of Federal, State, local authorities, and utility companies in force at the time of execution of contract.

B. Agencies or publications referenced herein refer to the following:

1. ADA: Americans with Disabilities Act

2. ANSI: American National Standards Institute

3. ASHRAE: American Society for Heating, Refrigeration, Air-Conditioning Engineers

4. ASTM: American Society for Testing and Materials

5. BICSI: Building Industry Consulting Services International

6. EIA: Electronic Industries Association

7. FCC: Federal Communications Commission

8. ICEA: Insulated Cable Engineers Association

9. IEEE: Institute of Electrical & Electronics Engineers

10. ISO: International Organization for Standards

11. NEC: National Electrical Code (2020)

12. NECA: National Electrical Contractors Association

13. NEMA National Electrical Manufacturers Association

14. NETA: National Electrical Testing Association

15. NIST: National Institute of Standards & Technology

16. OSHA: Occupational Safety and Health Administration

17. TIA: Telecommunications Industries Association

18. UL: Underwriters Laboratories, Inc.

1.3 DEFINITIONS

A. AHU: Air Handling Unit

B. ATC: Automatic Temperature Control

C. ATU: Air terminal Unit

D. AWG: American Wire Gauge (standard wire size measurement)

E. BAS/BMS: Building Automation System/Building Management System.

F. Device: Intelligent controller or other automated monitoring piece of equipment

G. CD: Compact Disc used for data storage

H. Commissioning Process to ensure installation and functionality is per design

I. Enterprise: Top level of integrated systems for overall logistical monitoring and business planning

J. EMS: Enterprise Management System

K. FCU: Fan Coil Unit

L. PLC: Programmable Logic Controller

M. I/O: Hardware inputs and outputs

N. Instrument: Device used to sense inputs or control outputs or both

O. Integration: Connection of disparate systems to a common platform using communication protocols.

P. IP Address: Internet Protocol node address

Q. IT: Information Technologies

R. O&M: Operation & Maintenance Manuals

S. Object: Hardware or Software component such as a device or point.

T. Point: Single hardware input/output or software data objects such as set points and attributes.

U. Point list: List of inputs, outputs and parameters for specific systems.

V. RFI: Request for Interpretation.

W. Stand-Alone: the ability to function upon loss of communication.

1.4 SYSTEM DESCRIPTION

A. The Air Handler control system includes integration, control and monitoring HVAC air handlers’ systems the facility including the following:

1. Air Handlers shown on the contract drawings.

2. All control dampers as shown on the P&ID drawings.

3. All instrumentation and accessory hardware shown on the P&ID drawings.

4. All variable frequency drives and control panels as shown on the P&ID drawings.

5. All PLC hardware and control panels as detailed in the specifications.

6. All electrically operated valves as shown on the P&ID drawings.

7. All modulating control valves as shown in the P&ID drawings.

8. Local operator interface terminals required for local control and monitoring.

9. Humidification systems shown on the contract drawings.

1.5 CONTRACTOR REQUIREMENTS

A. Air Handler control systems include but is not limited to labor and materials for terminations, pathways, installations, certifications, testing, system verification, project commissioning, network termination to GPO supplied network hardware, integration equipment, instrumentation and controls and integrated automated systems. The contractor is required to provide the following:

1. Procurement and installation of integrated automated systems hardware.

2. Procurement and installation of automation systems SCADA software if specified in other sections.

3. Integration of equipment systems with the automation systems SCADA software. This includes equipment supplied by others as shown in contract drawings.

4. Provide a PLC control systems for each air handler.

5. Procurement of ancillary equipment installed by others. This includes but is not limited to: labor and materials for terminations, pathways, installations, certifications, testing, system verification, project commissioning, instrumentation and controls and integrated automated systems.

6. Controls contractor is required to furnish and install the following, and is responsible for the equipment and software as shown below as well as the contract documents.

a. PLC control cabinets completely wired and tested before shipment. Main power feeds by electrical contractor. Field wiring by controls contractor or electrical contractor under the supervision of the control’s contractor.

b. VFD control panels completely wired and tested before shipment. Main power feeds by electrical contractor. Field wiring by controls contractor or electrical contractor under the supervision of the control’s contractor.

c. Field mounted line or load reactors or harmonic filters for VFD’s

d. All control valves and actuators with position feedback Valves shown in the specs and on the contract drawings. Valves installed by piping contractor.

e. All temperature and humidity sensors shown in the specs and on the contract drawings. Provide all mounting accessories and thermowells for pipe mounting of temperature transmitters and humidity sensors.

f. All magnetic flowmeters. Installed by piping contractor.

g. Differential pressure transmitters. To be installed by piping contractor.

h. Filter Differential pressure transmitters.

i. Pressure transmitters as specified or as shown on contract drawings. Provide block and bleed valves for all pressure transmitters.

j. Any PLC and VFD panel supplemental air conditioners that may be shipped loose and field installed by the contractor.

k. Computer equipment mounted in control panels as shown on contract drawings, or as specified in other sections.

l. SCADA software if shown on contract drawings or as specified in other sections.

m. Computer Servers and workstations as shown on the contract drawings or as specified in other sections.

n. UPS systems if shown on the contract drawings.

o. Any owner supplied equipment as specified in the contract documents.

p. All Ethernet cabling from GPO supplied network equipment. Contractor will coordinate with owner on cable labeling requirements.

1.6 SUBMITTALS

A. Contractor is to submit a complete schedule of submissions before submittal process.

B. Submit each section independent and separate from other sections. For each product submission: contractor is to provide specification section and product number.

C. Include only products within referenced specification section submission.

D. Product Data: For each product submission, include the following:

1. Table of contents for each submission.

2. Submit each section independent and separate from other sections. Include only products within referenced specification section submission.

3. Product data sheets for all required components and accessories.

4. Submit manufactures checklist & calibration documentation for calibrated instrumentation.

5. Identify actual product model number used for each drawing.

6. Identify any proposed modifications to system design. (Specifications or Drawings)

7. Organize product data based on specification Section, Part, and Article.

8. A paragraph-by-paragraph specification compliance report indicating compliance for each numbered paragraph. The following format shall be used in completing the compliance report:

9. Comply—without exception.

10. Qualify—meet the functional intent. For each paragraph, the contractor shall identify all differences in specific functions stated in the given paragraph and provide a description of what is excluded or how the qualifying system will meet the function specified.

11. Does not comply—cannot meet specified function.

E. Integration Plan:

1. Provide coordination efforts to accommodate complete integration of systems including:

2. Submit PLC ladder logic for review.

3. Submit maintenance schedules for all controller, valves, dampers, and instrumentation.

4. Complete set of control and wring diagrams. Include panel layout drawings if not shown on contract drawings.

F. Start-up Plan

1. Provide complete start up plan

2. Coordination of equipment controlled and monitored

3. Workflow process to start equipment

4. Equipment start-up requirements

5. Checklist

6. Intended sequence of work items

7. Start dates of individual work items

8. Duration of individual work items

9. Planned delivery dates for major material and equipment, and expected lead times

10. Milestones indicating possible restraints on work by other trades or situations

11. Coordinate equipment startup to coincide with construction schedules.

12. Provide multiple startup and commissioning trips at no additional cost to owner to allow for phased startup of the mechanical systems.

G. Owner Instruction and Training Plan

1. Provide organized list of specific equipment or systems that require training

2. Separate agenda for each training session including but be not limited to:

3. Construction Document review of systems

4. Installation and as-built conditions

5. Theory of operation

6. Demonstration of operation

7. Operation and Maintenance Document

8. Servicing and Maintenance Schedules

9. Interlocks and Safeties

10. Recommended classroom training and schedule.

H. Record Documents:

1. Include field condition updates.

2. Document material, make and model numbers where appropriate.

3. Update details, schedules, risers, etc.

4. I/O point as-built drawings for control panels.

5. Sequence details, modifications, or updates.

6. Control loops including final set-points and parameters

7. Mark and detail on coordination drawings, exact locations of equipment installed

8. Panel details for each unique panel

9. PLC program backups

10. Operator interface screen program backups.

11. SCADA application program backups.

12. All passwords and security configuration for all hardware and software.

13. All configuration and programming software for all controls as specified by owner and contract documents. Provide all passwords for all applications.

I. O&M Manuals:

1. O&M manuals for all equipment supplied under this contract. Include complete parts lists and bill of materials for PLC control panels and VFD panels.

2. At minimum, submit two electronic copies and four hard copies.

3. Do not include previously submitted product data.

4. Include a table of contents.

5. Tab manual based on specification chapters or sections.

6. Network architecture and communications concepts/diagrams.

7. Uploading and downloading software to the field hardware.

8. Finely detailed descriptions of all software programs.

9. Complete set of software engineering manuals.

10. Complete system design and engineering manual same as used by manufactures personnel.

11. Application Programming.

12. CD of any configuration tools used in project

13. Operator instructions or User Manual.

14. Calibration and/or verification sheets for ALL instrumentation including but not limited to:

15. Liquid Flow Meters

16. Air or gas Flow Meters

17. CO2 Sensors

18. Temperature Sensors

19. Humidity Sensors

20. Pressure transmitters

21. Differential pressure transmitters

22. Airflow monitoring stations.

23. Project Maintenance Manuals:

24. Include a table of contents

25. 1 copy on CD three hard copies

26. Organize by manual by specification section number

27. Index sheet listing contents in alphabetical order

28. Include the following:

29. Installation instructions

30. Manufacturer's operating and maintenance instructions (not product submittals)

31. Factory and field-test records, including calibration and factory setup

32. Printout of application control programs, one electronic copy and 2 hard copies.

33. Snapshot printout of each system installed

34. Signed checklist of each system showing complete I/O checkout and system commissioning.

35. Training schedule and course description catalog

36. Archived backup of software, drawings, and record documents

37. Installation contractor and service representative information

38. All passwords, licensing and warranty information for all provided software and hardware.

39. Documentation verifying all software licenses have been transferred to GPO.

J. Submit a User Workstation Planning Session Plan for each subject.

1. Graphics Generation following GPO standards for HMI design.

2. Tag naming.

3. Alarm management.

4. Report Configuration.

1.7 QUALITY ASSURANCE

A. All systems, equipment, components, accessories, and installation hardware must be new, free from defects, and currently in production.

B. All work shall be compliant with applicable national and local codes.

C. Demonstrate project compliance to Engineers satisfaction including construction and integration.

D. Provide the same manufacturer components of a given type product throughout project.

E. Support future compatibility for no less than 15 years with the ability to upgrade existing field panels and extend new field panels on an installed network.

F. Digital equipment furnished under this contract shall have been tested and made to comply with limits of Class A computing device pursuant to Subpart J of Part 15 of FCC Rules.

G. Maintain NEC workspace clearances.

1. Install and operationally check systems utilizing factory-trained competent technicians skilled in the setting and adjustment of equipment used in this project.

H. Test, adjust, and calibrate all end instruments before startup and commissioning.

I. Follow project communication protocol for all correspondence. Any changes, decisions, etc. must be properly documented. The Engineer will not issue verbal directions. Verbal interpretations, clarifications, conversations, etc. are non-binding without proper documentation.

I. Request for Interpretation (RFI) shall include:

1. Referenced drawing and/or Specification Section number.

2. Single request per RFI

3. Single proposed solution per RFI

4. Attached sketch of solution (if applicable)

5. Attached specification verbiage (if applicable)

6. Incomplete RFI’s will be returned without response.

7. Contact person.

J. RFI answers are for clarification only and do not authorize additional work or change orders.

K. Install devices in appropriate enclosure and in an accessible location.

L. Install systems and devices in a neat, workmanlike manner and in accordance with manufacturer's recommendations.

M. Continually monitor the field installation for code compliance and quality workmanship.

N. Remove and re-install any systems or devices where installation is deemed of poor quality by Owner or Engineer.

O. Provide software and firmware updates prior to and within 2 months of substantial completion.

P. Lead the coordination effort to ensure integration of various systems prior to installation.

Q. Comply with all health and safety regulations.

R. Include automatic restart logic for loss of power, safeties, fire alarm shutdown, etc.

S. Provide components not specifically indicated or specified, but necessary to make system function within the intent of contract documents.

T. All electrical products to be listed and labeled by UL and comply with NEMA Standards.

U. Provide a competent and experienced Project Manager

V. Engineering services shall be performed by factory-trained engineers.

W. System shall be installed by factory trained mechanical and electrical installers either in direct employ of this Contractor or by subcontractors who are under direct supervision of this Contractor.

X. Use only manufacturer trained technicians who are skilled, experienced, trained, and familiar with the specific equipment, software and configurations to be provided under this section.

Y. Coordinate with the Owner to ensure that the control system will perform on the Owner’s network environment without disruption to any of the other activities taking place on that LAN.

END OF SECTION

PART 2 INSTALLATION AND COMMISSIONING

2.0 DELIVERY, STORAGE, AND HANDLING

A. Store products according to manufacturer's recommendations.

B. Store products in original manufacturers packaging.

C. All material shall be stored in a climate controlled environment

D. Do not store products more than 3 months prior to schedule installation.

E. Coordinate deliveries of material with construction schedule and appropriate trades.

2.1 SCHEDULING

A. Included in this project are connections to equipment provided by others. Coordinate deliveries, final locations, factory mounting, and various connections required.

B. Coordinate activities with contract project schedule.

1. Ensure integration activities are incorporated into project schedule.

2. Communicate requirements to prevent potential damage from paint, dust, water, weather, etc.

3. Monitor and take measures to assure protection for all equipment.

4. Coordinate all IT requirements with owner and contract project schedule.

2.2 WARRANTY

A. Submit warranty documentation upon completion of project or phase and acceptance by Engineer and Owner.

1. Warranty start date shall be the date of completion for each control system.

Control must be system fully commissioned and all punch list items complete.

2. Warranty period shall be 1 year on parts and labor and include 2 years of software upgrades.

B. Repair or replace systems or parts found defective at no cost to Owner including but not limited to:

1. Operator workstation software, project-specific software, graphic software, database software, and firmware updates that resolve known software deficiencies as identified by the contractor shall be provided at no charge during the warranty period.

2. All corrective software modifications made during the warranty period shall be updated on all user documentation and on user and manufacturer archived software disks.

3. Include parts, labor, and necessary travel during warranty.

C. Scheduled preventive maintenance (p.m.) visit twice a year during the warranty period to audit system performance.

1. Each p.m. visit shall include exercising each control loop and control sequence for performance.

2. A log of each loop tested and each control sequence verified shall be reviewed with the Owner.

D. Provide vendor specific warranty information.

E. Provide services incidental to proper performance.

2.3 SYSTEM STARTUP

A. Start equipment according to manufactures recommendation.

B. Document system start up time and date.

C. Document person(s) performing startup.

D. Coordinate startup with other trades.

E. All equipment installation is to be complete before startup.

2.4 OWNER’S INSTRUCTIONS

A. Provide a factory-trained instructor to give full instructions to designated personnel in the operation, maintenance, and programming of each piece of equipment or system.

Instructors shall be thoroughly familiar with all aspects of the subject matter.

B. The training shall be specifically oriented to the system and interfacing equipment installed.

C. Include classroom instruction and field demonstration.

D. Classroom instruction should include at a minimum:

1. Detailed review of and as-built documentation and conditions

2. In depth discussion of theory or sequence of operations

3. Review organization and usability of O&M documentation

4. Maintenance procedures and schedules

E. Field instruction should include at a minimum

1. Normal maintenance procedures

2. Demonstration of operation

3. Demonstration of safeties and interlocks

2.5 COMMISSIONING

A. Participate in the commissioning process.

B. Provide on-site programming support throughout the commissioning process to make program modifications as directed by the commissioning engineer.

C. Provide documentation in final O&M package that reflects any changes made during the commissioning process.

D. Provide necessary personnel during the commissioning process to test and validate all field devices and PLC I/O.

E. Provide on-site start up support for each phase of equipment startup as well as final system commissioning.

PART 3 - PRODUCTS

3.1 General Control Products

A. GPO has standardized on Allen Bradley Controls as the basis for all building monitoring and production control systems. GPO has standardized on Inductive Automation Ignition software for HMI Visualization and monitoring software. GPO has invested significant capital in training, software and support agreements; therefore the use of alternate equipment and software is not permitted.

B. All control systems shall be based upon the Allen Bradley Control Logix platform. This includes all equipment and systems detailed in section 1.4.

C. Allen Bradley Control hardware.

1. The processors shall be Control Logix 5580 series processors.

2. Provide a minimum of 2 spare I/O modules of each type in each rack or 20% spare rack space for each I/O rack. Provide 20% Spare I/O of each type.

3. Provide 1756-PA75 series power supplies for common spare parts inventory.

4. Analog input modules shall be 1756-IF16. Modules shall be configured for single ended current mode. Provide 1492-AIFM8-3 interface module and prewired factory assembled cable.

5. Analog output modules shall be 1756-OF8. Module shall be configured for current output mode. 1492-AIFM8-3 interface module and prewired factory assembled cable.

6. Digital input modules shall be 1756-IA16 or 1756-IB16. Provide 1492-IFM20 interface module and prewired factory assembled cable.

7. Digital output modules shall be 1756-OA16. Provide 1492-XIM20120-16R Relay interface module and pre-wired factory assembled cable.

8. Provide din rail mounted signal conditioners to provide isolation for analog inputs from field devices that are powered from separate DC supply or self-powered.

9. 24VDC DC power supplies shall be equivalent to Allen Bradley 1606-XLE240E. Power supply shall have a mean time between failure (MTBF) of 1,058,000 hours at 24VDC and 10 amps (full load). All power supplies shall be UL listed. Substitute power supplies shall be shall only be provided with the GPO approval during shop drawing review.

10. Miniature circuit breakers shall be one, two or three pole design. UL 489 listed.

a. Dual rated for AC or DC applications.

b. DIN rail mounted miniature circuit breakers up to 63-amp current rating.

c. Current limiting design to provide fast short circuit interruption. that reduces the

d. Suitable for reverse feed applications

e. Suitable for branch circuit device

f. Fulfills UL 489, CSA C22.2 No.5 as well as IEC 60947-2 Standards.

g. Thermal-magnetic overcurrent protection

h. Three levels of short circuit protection, categorized by B, C and D curves.

i. SWD (switching duty) rated circuit protection.

j. Size breakers and trip curve in accordance with UL 508A.

k. Circuit breakers are not allowed on motor loads with the exception of electrically operated valves and dampers. All other motor loads will be protected with class J fuses.

11. Terminal blocks shall be screw type, din rail mountable and UL listed. Terminal blocks shall be rated at a minimum of 30 amps at 600 Volts and shall accommodate wire sizes of 24 to

10 AWG.

12. Terminal blocks for wires larger than 12 AWG shall be screw type, din rail mountable and UL listed. Terminal blocks shall be rated for 130 Amps at 600 volt and shall accommodate wire sizes of 14 to 1/0 AWG.

13. Grounding terminal blocks shall be green/ yellow in color din rail mountable, and UL listed. Grounding terminal blocks shall be rated at a minimum of 35 amps at 600 volts and shall accommodate wire sizes of 26 to 10 AWG.

14. Grounding terminal blocks for wires larger than 12 AWG shall be screw type, din rail mountable and UL listed. Terminal blocks shall be rated for 130 Amps at 600 Volts and shall accommodate wire sizes of 14 to 1/0 AWG.

15. All terminal blocks shall have a short circuit rating of no less than 100KA per UL 508A.

16. Terminal blocks and other panel components shall be mounted on din rail. Din rail shall be 35 mm x 7.5 mm Zinc-Plated Clear Chromated Steel and be UL listed.

17. I/O interface modules shall be mounted on elevated din rail. Elevated din rail shall be Symmetrical Rail 35 mm x 7.5 mm 2.26 in. (57.4 mm) high 3.28 ft. (1 m) long Copper-Free Aluminum and UL listed.

18. Push Buttons shall be 30 mm Allen Bradley 800H- series. No substitutions. Provide 2 NC –NO contact blocks for each operator. Button colors shall be green for start motor applications, red extended head for motor stop applications and black for general control functions. Provide other colors as determined by owner.

19. Selector switches shall be 30 mm Allen Bradley 800H series with standard operators. No substitutions Provide 1 NC-NO contact for each position.

20. Pilot lights shall be 30 mm Allen Bradley 800H series full voltage (12 to 130 Volt AC/DC) LED indicators. No substitutions. Provide color coded lenses for the following functions. Red indicates fault condition, Green indicates run or normal condition, blue indicates automatic mode, amber indicates manual or bypass mode. Provide color coded lenses as shown on contract drawings.

21. Provide all push buttons, selector switches and pilot lights with engraved legend plates.

Plates shall be 2.25” X 2.25” square “automotive style” White with black letters. Legend plates shall be suitable for outdoor use. Emergency stop legend plates shall be yellow with black letters.

3.2 LOCAL OPERATOR INTERFACE TOUCH SCREENS

Part 1 GENERAL

1.01 SUMMARY

A. Each PLC cabinet shall be equipped with a local Operator interface screen (HMI).

B. Coordinate screen development with owner. Follow owners design standards for interface screens.

1.02 RELATED SECTIONS

A. Section 26 05 00 – Common Work Results for Electrical

B. Section 26 00 00 – Electrical – General Provisions

C. Section 23 00 00 – Heating, Ventilating and Air Conditioning

1.03 REFERENCES

A. National Fire Protection Association - NFPA 70 - US National Electrical Code.

B. National Electrical Manufacturers Association - NEMA 250 - Enclosures for Electrical Equipment.

C. Underwriters Laboratory Inc. – UL 508.

E. International Electrical Code - IEC 146.

F. Institute of Electrical and Electronics Engineers, Inc. - IEEE 519 - IEEE Standard Practices and Requirements for Harmonic Control in Electrical Power Systems.

1.04 SUBMITTALS

A. Submit under provisions of Section 01 30 00

B. Shop Drawings – Approval.

C. Data Sheet and installation instructions.

D. HMI Screens application programs.

1.05 PRODUCTS

A. Allen Bradley PanelView Plus. Catalog number 2711P-T10C21D8S.

B. Allen Bradley PanelView 5000. Catalog number 2713P -T10CD1.

C. Allen Bradley PanelView 5000. Catalog number 2715P-T10CD.

D. Maple Systems Headless HMI cMT-FHDX-820 with Hope Industrial Systems 19” Monitor. Catalog number HIS-ML19-CTBH.

VARIABLE-FREQUENCY MOTOR CONTROLLER

PART 1 GENERAL

1.01 SUMMARY

A. The Variable Frequency Drive (VFD) system shall contain all components required to meet the performance, protection, safety and certification criteria of this specification.

B. The Variable Frequency Drive systems shall be provided by the controls contractor.

1.02 RELATED SECTIONS

A. Section 26 05 00 – Common Work Results for Electrical

B. Section 26 00 00 – Electrical – General Provisions

C. Section 23 00 00 – Heating, Ventilating and Air Conditioning

1.03 REFERENCES

A. National Fire Protection Association - NFPA 70 - US National Electrical Code.

B. National Electrical Manufacturers Association - NEMA 250 - Enclosures for Electrical Equipment.

C. Underwriters Laboratory Inc. – UL 508.

D. Canadian Standards Association International – CAN/CSA-C22.2 No. 14-05.

E. International Electrical Code - IEC 146.

F. Institute of Electrical and Electronics Engineers, Inc. - IEEE 519 - IEEE Standard Practices and Requirements for Harmonic Control in Electrical Power Systems.

1.04 SUBMITTALS

A. Submit under provisions of Section 01 30 00

B. Shop Drawings - Approval

1. Elevation Drawings: Include dimensional information and conduit routing locations.

2. Unit Descriptions: Include amperage ratings, enclosure ratings, fault ratings, nameplate information, etc. as required for approval.

C. Wiring Diagrams:

1. Power Diagram: Include amperage ratings, circuit breaker frame sizes, circuit breaker continuous amp ratings, etc. as required for approval.

2. Control Diagram: Include disconnect devices, pilot devices, etc.

3. Major components list.

C. Product Data Sheets

1. VFD and Operator Interface publications.

2. Data sheets and publications on all major components including but not limited to the following:

1. Contactors

2. Fuses (power and control)

3. Control power transformers

4. Pilot devices

5. Relays/Timers

6. Test procedures shall be per the manufacturer’s standards.

1.05 CLOSEOUT SUBMITTALS (OPERATION AND MAINTENANCE MANUALS)

A. Submit under provisions of Section 01 30 00

B. Shop Drawings – Final as shipped

1. Elevation Drawings: Include dimensional information and conduit routing locations.

2. Unit Descriptions: Include amperage ratings, enclosure ratings, fault ratings, nameplate information, etc. as required for approval.

3. Wiring Diagrams:

4. Power Diagram: Include amperage ratings, power fuses continuous amp ratings, etc. as required for approval.

5. Control Diagram: Include disconnect devices, pilot devices, etc.

6. Major components list.

C. Product Data Sheets

1. VFD and Operator Interface publications.

D. Data sheets and publications on all major components including but not limited to the following:

1. Contactors

2. Fuses (power and control)

3. Control power transformers

4 Pilot devices

5. Relays/Timers

E. Test procedures shall be per the manufacturer’s standards.

F. Operation and Maintenance Data

1. Service and Contact information

2. VFD and Operator Interface User Manuals

3. Troubleshooting / Service Manuals

1.06 QUALITY ASSURANCE

A. Qualifications:

1. Manufacturers: Allen Bradley PowerFlex 755. No substitutions.

2. The VFD and all associated optional equipment shall be UL listed or recognized.

3. All inspection and testing procedures shall be developed and controlled under the guidelines of the Supplier’s quality system and must be registered to ISO 9001 and regularly reviewed and audited by a third-party registrar.

4. The VFD shall be pre-wired, assembled and tested as a complete package.

5. The VFD shall be sided for heavy duty service.

1.07 DELIVERY, STORAGE, AND HANDLING

A. Contractor shall coordinate the shipping of equipment with the manufacturer.

B. Contractor shall store the equipment in a clean and dry space at an ambient temperature range of -40 °C to 70 °C (-40 °F to 158 °F).

C. The contractor shall protect the units from dirt, water, construction debris and traffic.

1.08 WARRANTY

A. The manufacturer shall provide their standard parts warranty for eighteen (18) months from the date of shipment or twelve (12) months from the date of being energized, whichever occurs first.

B. This warranty applies to variable-frequency drive systems.

PART 2 PRODUCTS

2.01 MANUFACTURERS

A. Allen-Bradley® – PowerFlex® 755 VFD (No substitutions)

2.02 VARIABLE FREQUENCY DRIVE UNIT

A. Features

1. Certifications

2. Listed to UL508C and CAN/CSA-C22.2 No. 14-05

3. In conformity with EMC Directive (2004/108/EC) and Low Voltage Directive (2006/95/EC). Standards applied; EN 61800-3:2004, EN 61800-5-1:2007

4. TÜV Rheinland - standards applied: EN 61800-3:2004, EN 61800-5-1:2007, EN ISO 13849-1:2008, EN ISO 13849-2:2003, EN 61800-5-2:2007, EN 61508 PARTS 1-7:2000, EN 62061:2005, and EN 60204-1:2006

5. Australian Communications and Media Authority. In conformity with Radio communications Act: 1992, Radio communications Standard: 2008, and Radio communications Labeling Notice: 2008. Standards applied: EN 61800-3:2004

6. Electric Power Research Institute. Certified compliant with standards SEMI F47 and IEC 61000-4-34

7. Russian GOST-R Certificate No. POCC US.ME92.H00040

8. American Bureau of Shipping (ABS) Certificate 11-HS743429-PDA

9. Lloyd’s Register Type Approval certificate 11/60008

10. RINA Certificate ELE349811CS

B. Hardware

1. Utilize diode bridge or SCR bridge on the input rectifier.

2. Utilize DC bus inductor on all six-pulse VFD’s only.

3. Utilize switching logic power supply operating from the DC bus.

4. Incorporate phase to phase and phase to ground MOV protection on the AC input line.

5. Utilize gold plated plug-in connections on printed circuit boards.

6. Microprocessor-based inverter logic shall be isolated from power circuits.

7. Utilize latest generation IGBT inverter section.

8. Inverter section shall not require commutation capacitors.

9. Embedded Ethernet port for direct network cable connections.

10. Battery receptacle for Lithium battery power to the Real Time Clock.

11. Additional DPI port for handheld and remote HIM options.

12. Dedicated Digital Input for hardware enable.

13. Conformal coated printed circuit boards.

14. Optional onboard 24V DC Auxiliary Control Power Supply when required.

D. Control Logic

1. Ability to operate with motor disconnected.

2. Provide a controlled shut down, when properly protected, with no component failure in the event of an output phase to phase or phase to ground short circuit. Provide annunciation of the fault condition.

3. Provide multiple programmable stop modes including Ramp, Coast, DC-Brake, Ramp-to-Hold, Fast Braking, and Current Limit Stop.

4. Provide multiple acceleration and deceleration rates.

5. Adjustable output frequency up to 590 Hz.

E. DeviceLogix™ Control

1. Ability to control outputs and manage status information locally within the VFD.

2. Ability to function stand-alone or complimentary to supervisory control.

3. Ability to speed reaction time by processing in the VFD.

4. Ability to provide scaling, selector switches, or other data manipulations not already built into the VFD.

5. Ability to read inputs/write outputs and exclusively control the VFD.

6. Ability to provide an option for decision making if communication is lost with main controller.

7. Ability to control other VFD’s via a peer-to-peer EtherNet/IP network.

8. Ability to write programs off-line.

F. Motor Control Modes

1. Selectable Sensorless Vector, Flux Vector, V/Hz, Interior Permanent Magnet Motor, Surface Mount Permanent Magnet Motor, and Adjustable Voltage Control modes selectable through programming.

2. The drive shall be supplied with a Start-up and Auto-tune mode.

3. The V/Hz mode shall be programmable for fan curve or full custom patterns.

4. Capable of Open Loop V/Hz.

G. Current Limit

1. Programmable current limit from 20% to 160% of rated output current.

2. Current limit shall be active for all drive states: accelerating, constant speed and decelerating.

3. The drive shall employ PI regulation with an adjustable gain for smooth transition in and out of current limit.

H. Acceleration / Deceleration

1. Accel/Decel settings shall provide separate adjustments to allow either setting to be adjusted from 0 to 3600 seconds.

2. A second set of remotely selectable accel/decel settings shall be accessible through digital inputs.

I. Speed Profiles

1. Programming capability shall allow the user to produce speed profiles with linear acceleration/deceleration or "S Curve" profiles that provide changing accel/decel rates.

2. S Curve profiles shall be adjustable.

J. Adjustments

1. A digital interface can be used for all set-up, operation and adjustment settings.

2. All adjustments shall be stored in nonvolatile memory.

3. No potentiometer adjustments shall be required.

4. Nonvolatile memory for factory default values shall be provided.

5. Software must be available for trending and diagnostics, as well as online and offline programming functionality.

K. Process PID Control

1. The drive shall incorporate an internal process PI regulator with proportional and integral gain adjustments as well as error inversion and output clamping functions.

2. The feedback shall be configurable for normal or square root functions. If the feedback indicates that the process is moving away from the set-point, the regulator shall adjust the drive output until the feedback equals the reference.

3. Process control shall be capable of being enabled or disabled with a hardwire input. Transitioning in and out of process control shall be capable of being tuned for faster response by preloading the integrator.

4. Protection shall be provided for a loss of feedback or reference signal.

L. Skip Frequencies

1. Three adjustable set points that lock out continuous operation at frequencies, which may produce mechanical resonance shall be provided.

2. The set points shall have a bandwidth adjustable from Maximum Reverse Speed to Maximum Forward Speed.

M. Fault Reset / Run

1. When the drive is running or idle, it shall provide up to nine automatic fault reset and restarts following a fault condition before locking out and requiring manual restart.

2. The automatic mode shall not be applicable to shorted output faults and other internal microprocessor faults.

3. The time between restarts shall be adjustable from 0.5 seconds to 30 seconds.

N. Run on Power Up

1. A user programmable restart function shall be provided to allow restart of the equipment after restoration of power after long duration power outages. Restart time dependent on presence of incoming signal.

O. Fault Memory

1. The last 32 fault codes shall be stored and time stamped in a fault buffer.

2. Information about the drive’s condition at the time of the last fault such as operating frequency, output current, DC bus voltage and twenty-seven other status conditions shall be stored.

3. A power-up marker shall be provided at each power-up time to aid in analyzing fault data.

4. The last 32 alarm codes shall be stored and time stamped for additional troubleshooting reference.

P. Overload Protection

1. The drive shall provide internal class 10 adjustable overload protection.

2. Overload protection shall be speed-sensitive and adjustable.

3. A viewable parameter shall store the overload usage.

Q. Auto Economizer

1. An auto economizer feature shall be available to automatically reduce the output voltage when the drive is operating in an idle mode (drive output current less than programmed motor FLA). The voltage shall be reduced to minimize flux current in a lightly loaded motor thus reducing kW usage.

2. When the load increases, the drive shall automatically return to normal operation.

R. Terminal Blocks

1. For frames 1 to 7, a separate terminal block shall be provided for power wiring.

2. For frames 8-10, power wiring is landed on robust L-brackets behind the drive unit. This wiring remains in-place if the drive unit is removed.

3. Terminal blocks shall be provided for control wiring on all frames

4. I/O terminal blocks shall be removable with wiring in place.

S. Flying Start

6. The drive shall be capable of determining the speed and direction of a spinning motor and adjust its output to "pick-up" the motor at the rotating speed. This feature should be enabled during startup.

S. Inputs and Outputs

1. The Input / Output option modules shall consist of both analog and digital I/O.

2. No jumpers or switches shall be required to configure digital inputs and outputs.

3. All digital input and output functions shall be fully programmable.

4. The control terminal blocks shall be rated for 600V AC.

5. Inputs shall be optically isolated from the drive control logic.

6. The control interface card shall provide input terminals for access to fixed drive functions that include start, stop, external fault, speed, and enable.

7. The VFD shall be capable of supporting up to 10 analog inputs, 10 analog outputs, 31 digital inputs, 10 relay outputs, 10 transistor outputs, and 5 positive temperature coefficient (PTC) inputs.

8. The Input / Output option modules shall have the following features:

9. Analog Inputs: Where specified

10. Quantity one (1) or two (2) differentially isolated, ±10V (bi-polar), 88k ohm input impedance, 11 bit plus sign.

11. Analog inputs shall be user programmable for a variety of uses including frequency command and process loop input. Analog inputs shall be user programmable for function scaling (including invert), offset, signal loss detect and square root.

12. Analog Outputs: Where specified

13. Quantity one (1) or two (2) ±10V (bi-polar) / 11 bit & sign, 2 k minimum load, 4- 20 mA, 11 bit plus sign, 400 maximum load.

14. The analog output shall be user programmable to be proportional to one of fourteen process parameters including output frequency, output current, encoder feedback, output power.

15. Programming shall be available to select either absolute or signed values of these parameters.

16. Digital Inputs: Where specified

17. Quantity three (3) or six (6) digital inputs rated 24VDC DC/115V AC.

18. All inputs shall be individually programmable for multiple functions including:

Start, Run, Stop, Auxiliary Fault, Speed Select, Jog and Process PI functions.

19. A single safety input (ATEX) shall be a configurable option for a thermostat or PTC temperature sensor.

20. Digital Outputs: Where specified

21. At a minimum one (1) relay output (N.O. or N.C.).

22. For 240V AC or 24V DC, N.O. contact output ratings shall be 2-amp max., general purpose (inductive)/resistive. N.C. contact output ratings shall be 2 amp max., resistive only.

23. Relays shall be programmable to multiple conditions including: Fault, Alarm, At Speed, Drive Ready and PI Excess Error.

24. Timers shall be available for each output to control the amount of time, after the occurring event, that the output relay actually changes state.

25. Transistor outputs are available in quantities varying from zero (0) to two (2).

26. For 24V DC, transistor output rating shall be 1 amp max, Resistive.

T. Reference Signals

1. The drive shall be capable of using the following input reference signals:

2. Analog inputs

3. Preset speeds

4. Remote potentiometer

5. Digital MOP

6. Human Interface Module

7. Communication networks

U. Loss of Reference

1. The drive shall be capable of sensing reference loss conditions.

2. In the event of loss of the reference signal, the drive shall be user programmable to the following:

3. Fault the drive and coast to stop.

4. Issue a minor fault - allows the drive to continue running while some types of faults are present.

5. Alarm and maintain last reference.

6. When using a communications network to control the drive, the communications adapter shall have these configurable responses to network disruptions and controller idle (fault or program) conditions:

7. Fault

8. Stop

9. Zero Data

10. Hold Last State

11. Send Fault Configuration

12. Coordinate with GPO to determine the proper configuration for each application.

W. Metering

1. At a minimum, the following parameters shall be accessible through the Human Interface Module:

2. Output Current in Amps

3. Output Voltage in Volts

4. Output Power in kW

5. Elapsed MWh

6. DC Bus Voltage

7. Frequency

8. Heatsink Temperature

9. Last eight (32) faults

10. Elapsed Run Time

11. IGBT Temperature

X. Faults

1. At a minimum, the following faults shall be accessible through the Human Interface Module:

2 Power Loss

3. Undervoltage

4. Overvoltage

5. Motor Overload

6. Heatsink Over-temperature

7. Maximum Retries

8. Phase to Phase and Phase to Ground Faults

Y. Predictive Diagnostics

1. At a minimum, the following predictive diagnostic features shall be provided:

2 Relay Output Life Cycles based on load type and Amps.

3. Hours of Fan Life based on load and ambient temperature.

4. Motor Bearing life based on expected hours of use.

5. Motor Lubrication schedule based on hours of use.

6. Machine bearing life based on expected hours of use.

Z. Real-Time Clock

1. Shall be capable of providing time stamped events.

2. Shall have the ability to be set locally or via a remote controller.

3. Shall provide the ability to be programmable for month, day, year and local time zones in HH:MM:SS.

AA. Programmable Logic Controller Integration.

1. The drive shall have the following specific features to enable integration with a Rockwell Automation® ControlLogix® Automation Controller.

2. Shall have an Add-on Profile available for use with Rockwell Automation Studio 5000® programming software.

3. Shall support Rockwell Automation controller’s Automatic Device Configuration functionality.

VARIABLE FREQUENCY DRIVE SYSTEMS

PART 1 GENERAL

1.01 SUMMARY

A. The Variable Frequency Drive (VFD) system shall contain all components required to meet the performance, protection, safety and certification criteria of this specification.

B. All Variable frequency Drives shall be Allen Bradley PowerFlex 755.

C. The Variable Frequency Drive systems shall be provided by the controls contractor.

D. Features

1. Ratings: The drive and all components shall have a SCCR rating of 100KIA.

2. Voltage

3. Capable of accepting nominal plant power of 400V, 480V, 600V or 690V AC at 50 Hz or 60 Hz.

4. The supply input voltage tolerance shall be ± 10% of nominal line voltage.

E. Displacement Power Factor

1. Six-pulse VFD shall be capable of maintaining a minimum true power factor (Displacement P.F. X Distortion P.F.) of 0.95 or better at rated load and nominal line voltage, over the entire speed range.

F. Efficiency

1. A minimum of 96.5% (+/- 1%) at 100% speed and 100% motor load at nominal line voltage.

2. Control power supplies, control circuits, and cooling fans shall be included in all loss calculations.

3. Operating ambient temperature range without derating: 0 °C to 40 °C (32 °F to 104 °F)

4. Operating relative humidity range shall be 5% to 95% non-condensing.

5. Operating elevation shall be up to 1000 Meters (3,300 ft) without derating.

G. Sizing

1. Drive selections shall be sized for Heavy-Duty loads.

2. Drives shall provide 150% overload capability for up to one minute and 180% for up to 3 seconds.

H. Auto Reset/Run

1. For faults other than those caused by a loss of power or any other non-critical fault, the drive system shall provide a means to automatically clear the fault and resume operation.

I. Ride-Through

1. The VFD system shall attempt to ride through power dips up to 20% of nominal.

The duration of ride-through shall be inversely proportional to load. For outages greater than 20%, the drive shall stop the motor and issue a power loss alarm signal to a process controller, which may be forwarded to an external alarm signaling device.

J. Run on Power Up

1. The VFD system shall provide circuitry to allow for remote restart of equipment after a power outage. Unless indicated in the contact drawings, faults due to power outages shall be remotely resettable. The VFD system shall indicate a loss of power to a process controller, which may be forwarded to an external alarm signaling device. Upon indication of power restoration the process controller will attempt to clear any faults and issue a run command, if desired.

K. Communications

1. VFD shall provide an embedded EtherNet/IP port.

2. VFD shall be capable of communicating on multiple networks.

3. VFD shall be capable of supporting the following network options as detailed in the specifications and drawings:

4. DeviceNet

5. EtherNet/IP ( required)

6. ControlNet Coax

7. ControlNet Fiber

8. Interbus

9. CANopen

10. Modbus/TCP

11. Modbus RTU

12. Profibus DP

13. RS-485 DF1

14. RS-485 HVAC

15. Remote I/O

16. Profinet I/O

17. BACnet/IP

L. Enclosure Door Mounted Human Interface Module (HIM)

1. An enclosure door-mounted HIM, rated NEMA/UL Type 1 or NEMA/UL Type 4/12, shall be provided for each VFD and Soft Start mounted in the drive enclosure.

2. The HIM shall have the following features:

3. A three (3) line by twenty-one (21) character backlit LCD display with graphics capability.

4. Shall indicate drive operating conditions, adjustments and fault indications.

5. Shall be configured to display in the following three distinct zones:

6. The top zone shall display the status of direction, drive condition, fault / alarm conditions and Auto / Manual mode.

7. The middle zone shall display drive output frequency.

8. The bottom zone shall be configurable as a display for either programming menus / information or as a two-line user display for two additional values utilizing scaled units.

9. Shall provide digital speed control.

10. The keypad shall include programming keys, drive operating keys (Start, Stop, Direction, Jog and Speed Control), and numeric keys for direct entry.

M. Enclosure

1. Shall be rated NEMA/UL Type (12).

2. Exterior drive cabinets shall be NEMA 4X stainless steel.

3. Shall be painted per the manufacturer’s standard.

4. Shall provide entry and exit locations for power cables.

5. The drive system nameplate shall be marked with system Short Circuit Current Rating (SCCR) and additional information to meet NFPA 70 409.110(4) 2018 Edition.

6. Provide closed loop air conditioner for each drive cabinet.

7. Air conditioner shall have a hermetically sealed compressor and utilize R-134 refrigerant.

8. Air conditioner shall be equipped with Active Condensate System using PTC heater element.

9. Air conditioner shall be equipped with washable, reusable 8-layer aluminum mesh filters.

10 Air conditioners shall be equipped with Digital Touchpad Programmable Controller, viewable and accessible from inside enclosure.

11. Air-conditioner shall be warrantied for a period of 2 years.

12. Provide thermoelectric heater/ coolers for drive cabinets located outdoors.

Thermoelectric cooler shall be NEMA 4X Stainless construction.

13. As an alternate, provide water cooled heat exchanger for VFD cabinets feeding air handlers or areas where chilled water is available. Run insulated chilled water supply and return piping to heat exchanger. Provide factory installed thermostat, water solenoid valve and alarm contact wired to PLC input. Heat exchanger to be Kooltronic KPHE Series Water-to-Air Panel- Mounted Heat Exchangers.

N. Drive Enclosure Input Disconnect

1. Provide an enclosure flange mounted interlocked disconnect with class J…